Overmolded electronic eyewear device frame

ABSTRACT

A process of overmolding a frame of a portable eyewear electronic device and a frame produced by the process is presented. A frame that includes a first material and includes a releasably mountable feature is attached to the mold in a desired position and does not contact other areas of the mold. The mold is filled with a second material to at least partially encase the frame insert.

TECHNICAL FIELD

Examples set forth in the present disclosure relate to portableelectronic devices, including wearable electronic devices such aseyeglasses. More particularly, but not by way of limitation, the presentdisclosure describes a method of overmolding an electronic eyeweardevice.

BACKGROUND

Many electronic devices available today include wearable consumerelectronic devices. Wearable consumer electronic devices have moldedparts. Molding methods are used to form the molded parts.

BRIEF DESCRIPTION OF THE DRAWINGS

Features of the various implementations disclosed will be readilyunderstood from the following detailed description, in which referenceis made to the appending drawing figures. A reference numeral is usedwith each element in the description and throughout the several views ofthe drawing. When a plurality of similar elements is present, a singlereference numeral may be assigned to like elements, with an addedlower-case letter referring to a specific element.

The various elements shown in the figures are not drawn to scale unlessotherwise indicated. The dimensions of the various elements may beenlarged or reduced in the interest of clarity. The several figuresdepict one or more implementations and are presented by way of exampleonly and should not be construed as limiting. Included in the drawingare the following figures:

FIG. 1 is a perspective view of a frame insert for an electronic eyeweardevice in accordance with an example.

FIG. 2 is a front view of the frame insert of FIG. 1 .

FIG. 3 is a back perspective view of the insert of FIGS. 1 and 2 .

FIG. 4 is a flowchart that depicts an example overmolding process for aframe insert of an electronic eyewear device.

FIGS. 5A and 5B, which are bottom and perspective cross-sectional viewstaken along line 5-5 of FIG. 2

FIG. 6A is a front perspective view that depicts an overmolded frameinsert of an electronic eyewear device produced in accordance with anexample of an overmolding process described herein.

FIG. 6B is a back perspective view of the overmolded electronic eyeweardevice of FIG. 6A.

FIG. 6C is a perspective sectional view taken along line 6C-6C of FIG.6A.

FIG. 7A is a front perspective view that depicts an overmolded frameinsert of an electronic eyewear device produced in accordance with anexample of an overmolding process described herein.

FIG. 7B is a partial cut away view taken along line 7B-7B of FIG. 7Ashowing additional detail.

FIG. 8A is a front perspective view that depicts an overmolded frameinsert of an electronic eyewear device produced in accordance with anexample of an overmolding process described herein.

FIG. 8B is a front elevation view of the overmolded frame insert of anelectronic eyewear device shown in FIG. 8A.

DETAILED DESCRIPTION

A process of overmolding a frame of a portable eyewear electronic deviceand a frame produced by the process is presented. A frame that includesa first material and includes a releasably mountable feature is attachedto the mold in a desired position and does not contact other areas ofthe mold. The mold is filled with a second material to at leastpartially encase the frame insert.

The following detailed description includes systems, methods,techniques, instruction sequences, and computing machine programproducts illustrative of examples set forth in the disclosure. Numerousdetails and examples are included for the purpose of providing athorough understanding of the disclosed subject matter and its relevantteachings. Those skilled in the relevant art, however, may understandhow to apply the relevant teachings without such details. Aspects of thedisclosed subject matter are not limited to the specific devices,systems, and method described because the relevant teachings can beapplied or practice in a variety of ways. The terminology andnomenclature used herein is for the purpose of describing particularaspects only and is not intended to be limiting. In general, well-knowninstruction instances, protocols, structures, and techniques are notnecessarily shown in detail.

The term “connect”, “connected”, “couple” and “coupled” as used hereinrefers to any logical, optical, physical, or electrical connection,including a link or the like by which the electrical or magnetic signalsproduced or supplied by one system element are imparted to anothercoupled or connected system element. Unless described otherwise, coupledor connected elements or devices are not necessarily directly connectedto one another and may be separated by intermediate components,elements, or communication media, one or more of which may modify,manipulate, or carry the electrical signals. The term “on” meansdirectly supported by an element or indirectly supported by the elementthrough another element integrated into or supported by the element.

Additional objects, advantages and novel features of the examples willbe set forth in part in the following description, and in part willbecome apparent to those skilled in the art upon examination of thefollowing and the accompanying drawings or may be learned by productionor operation of the examples. The objects and advantages of the presentsubject matter may be realized and attained by means of themethodologies, instrumentalities and combinations particularly pointedout in the appended claims.

Reference now is made in detail to the examples illustrated in theaccompanying drawings and discussed below.

Frames for electronic eyewear device are typically made using aninjection molding process that tends to have some drawbacks such as sinkmarks resulting from uneven wall thicknesses, moreover, electroniceyewear devices also may benefit from additional electronics to beplaced inside the frame insert but difficulties with integrating them inthe molding process increases cycle time and depending on the materialused may require temperatures detrimental to the integrity of thecomponent.

FIG. 1 is a perspective view and FIG. 2 is a front view of a frameinsert 100 for an example electronic eyewear device. The frame insert100 for the electronic eyewear device includes a frame 101 thatcomprises a bridge 102 and right and left eye lens rims 104, 106, and insome examples such as shown in FIGS. 1 and 2 , may also include rightand left side circumferential openings 108, 110, which are shown inFIGS. 1 and 2 near the hinge areas 112, 114, for receiving camera mountsand are also near right and left chunks (not shown) that may housevarious electronic components of the camera system such as circuitboards, wiring, etc. FIG. 3 is a back perspective view of the insert ofFIGS. 1 and 2 showing hinge areas 112, 114 in more detail along withright and left nose pad mounting surfaces 118, 120 in additional detail.

FIG. 4 is a flowchart that depicts the overmolding process for the frameinsert 100. At step 402, an electronic eyewear device frame insert 100that is composed of a first material 121. Materials that can be used into create the described insert include various metals, thermoplastics,some thermosets, and some elastomers. The selection of a substratematerial for creating the insert is based both upon the desiredcharacteristics of the insert, such as the degree of rigidity orflexibility for fitting to a wearer's head, retention of the shape, andthe processing parameters of the molding process. Different materialshave different properties that affect the strength and function of thefinal part and also dictate the processing parameters, including theinjection temperature, injection pressure, mold temperature, moltensubstrate viscosity, ejection temperature, and cycle time.

As mentioned above, thermoplastics are suitable for use. Thermoplasticsbecome pliable or moldable above a specific temperature and return to asolid state upon cooling. Most thermoplastics have a high molecularweight and molecular chains that associate through intermolecular forcesthat will spontaneously reform upon cooling, allowing thermoplasticmaterials to be remolded. Another material that can be used in injectionmolding is a thermosetting polymer. Unlike thermoplastics, thermosettingpolymers form irreversible chemical bonds during the curing process thatbreak down upon melting and do not reform upon cooling. In someexamples, the first material 121 is translucent and in others it isopaque.

In some examples, the frame insert 100 is made from a metal, metal alloyor metal composite composition or combination thereof, such as bymolding, stamping, milling or other suitable process.

Another feature of the materials used for the insert 100 is the hardnessof each material, which contributes to adjustability, strength andcomfort. Shore Hardness is measured using a Durometer, the InternationalStandard Instrument used to measure the hardness of rubber, rubber-likematerials or plastics. Durometers measure hardness by the penetration ofan indentor into the rubber/plastic sample. The calibrated reading isexpressed in a number value. The hardness values are always expressed interms of plus or minus (+/−) five points (example: 60+/−5 Durometer).There are 3 Durometer types and they relate to materials as Durometertype “A” is for the Shore Hardness of soft rubbers and plastics,Durometer type “D” is for the Shore Hardness of hard rubber and plasticsand Durometer type “00” is for the Shore Hardness of sponges and foam.In one example, the first material 121 has a Shore D Hardness betweenabout 80 and about 85. In one example, the first material 121 is atranslucent thermoplastic polyamide produced by EMS-Chemie, having ahardness of between about 80 and about 85 Shore D. In some examples thefirst material 121 is made of a thermoplastic material such as nylon,such as the nylon material is manufactured by EMS-GRIVORY, a unit ofEMS-CHEMIE AG, which is based in Switzerland and Sumter, S. C. A nylonmaterial has stronger thermal and mechanical properties than many othermaterials used for sunglass manufacturing. This is helpful becauseeyeglasses and sunglasses can be subjected to extreme climate conditionsranging from approximately −20° C. to approximately 110° C. and need tobe able to retain their shape.

Optionally, in some examples, the insert 100 may be modified to form apre-assembled or modified insert to include one or more parts, includingbut not limited to a flexible printed circuit board (PCB), antenna,heatsink, or various other parts suitable for an electronic eyeweardevice, and in some other examples, such parts include one or moredecorative features, designs, aspects, and the like. In some examples,insert 100 can itself could function as an antenna or heatsink.

The frame insert 100 also includes one or more releasably mountablefeature(s) that can be used as an attachment point(s) during the moldingprocess. For example, as shown in FIGS. 5A and 5B, which are bottom andperspective cross-sectional views taken along line 5-5 of FIG. 2 , anexample eye lens rim configuration includes a V-shaped lens groove 122,124, but similar undercut features that can be used to hold the insertwhile undergoing the overmolding process without interfering in coverageof the insert is also suitable. FIGS. 6A-6C also show the lens grooves122, 124. In some examples, the nose pad areas 128, 130 of nose padmounting surfaces 118, 120 as shown in FIGS. 1 and 2 can serve as pointsof contact to stabilize the insert in the mold.

At step 404, a mold is provided for the electronic eyewear device frameinsert 100. The mold can be one suitable for overmolding. Either ahorizontal or vertical injection molding machine can be used for theovermolding of the second material on the insert. In one example, avertical injection molding machine is used to overmold the secondmaterial on the insert. In another example, a horizontal injectionmolding machine is used to overmold the second material on the insert.

At steps 406 and 408, the frame insert is placed into the mold andreleasably mounted in a desired position and not contact other areas ofthe mold. In one example, the eye lens rim configuration provides areleasably mountable feature for releasable attachment to the mold whichdoes not interfere with overmolding of the remaining insert. In anotherexample, the camera mount openings can also be used in addition to, orinstead of the eye lens rims depending on their dimensions and supportcapability for the insert.

At step 410, after the insert is releasably attached to the mold, themold is filled with a second material in an amount sufficient to coverthe insert to a desired thickness. In one example, the insert part isdesigned to minimize wall thickness variation in the overmold secondmaterial for a desired appearance, making the initial appearance, whichtypically includes sink marks and other surface irregularities andblemishes, of the insert less important.

In one example, the first material, and the overmolded second material,have different Shore Hardness or are made from different materials, orboth. In one example, the first material 121 is a harder material with aShore D Hardness between 80 and 85 and the second material is a softermaterial with a Shore A Hardness between 60 and 70. In some examples,the first material 121 and second material have substantially the sameShore Hardness. In another example, the first material 121 is atranslucent thermoplastic polyamide produced by EMS-Chemie, having ahardness of between 80 and 85 Shore D and the second material having ahardness of between 60 and 70 Shore A. In yet another example, thesecond material is a rubber. In some examples, the second material is asilicone rubber. In one example, the second material has a hardness ofbetween 60 and 70 Shore A.

In some examples, colorants are added to the first material, added tothe second material, added to both, or added to neither to alter thecolor and overall appeal of the electronic eyewear device overmoldedframe.

At step 412, the second material at least partially encasing the frameinsert is allowed to solidify. In some examples, the second materialdoes not exceed 90% of the surface area of the insert and could cover aslittle as 5% of the area of the insert.

At step 414, the overmolded electronic eyewear device frame insert isremoved from the mold. FIGS. 6A-6C show examples of overmolded frameinserts produced by the described method. FIG. 6A is a front perspectiveview of an overmolded electronic eyewear device frame insert such thatthe second material 126 encases the front of the frame 101, except forright and left lens grooves 122, 124, the innermost circumferentialareas of the camera housing and nose-facing portions 128, 130 of thenose pads. In this example, the second material 126 is an opaquematerial.

FIG. 6B is a back perspective view of the overmolded electronic eyeweardevice of FIG. 6A showing build-up 132 of the second material 126 on thearea surrounding the camera circumferential opening 108 and follows theperimeter of chunks for the device and also shows the lack of encasementof an area 130 of nose pad mounting surface 118 as shown in FIG. 6A.FIG. 6C is a perspective sectional view taken along line 6C-6C of FIG.6A, which shows releasable mountable feature or attachment point orgroove 122.

FIG. 7A is a front perspective view that provides an example of aninsert that has been encased in a translucent second material 126 andFIG. 7B is a partial cut away view showing how the second material 126exhibits a substantially consistent wall thickness 134 while concealingimperfections in the surface of the overmolded insert.

FIGS. 8A and 8B are a front perspective view and a front elevation viewshowing an electronic eyewear device frame insert where the firstmaterial 121 may be opaque and/or decorated and is partially encasedwith the second material 126. In this example, the second material 126encases (as used herein “encases” includes covers or bonds to) the outerperimeter 136 of the frame and rims to provide a two-tone visualimpression. In some examples, the second material may cover less than10% of the surface area of frame insert 100. In other examples, thesecond material may cover less than 10%, 15%, 20%, 30%, 40%, 50%, 60%,70%, 80%, 90%, or 95% of the surface area of frame insert 100 In someexamples, a third material could be subsequently overmolded to form a“second overmolded” frame insert.

Except as stated immediately above, nothing that has been stated orillustrated is intended or should be interpreted to cause a dedicationof any component, step, feature, object, benefit, advantage, orequivalent to the public, regardless of whether it is or is not recitedin the claims.

It will be understood that the terms and expressions used herein havethe ordinary meaning as is accorded to such terms and expressions withrespect to their corresponding respective areas of inquiry and studyexcept where specific meanings have otherwise been set forth herein.Relational terms such as first and second and the like may be usedsolely to distinguish one entity or action from another withoutnecessarily requiring or implying any actual such relationship or orderbetween such entities or actions. The terms “comprises,” “comprising,”“includes,” “including,” or any other variation thereof, are intended tocover a non-exclusive inclusion, such that a process, method, article,or apparatus that comprises or includes a list of elements or steps doesnot include only those elements or steps but may include other elementsor steps not expressly listed or inherent to such process, method,article, or apparatus. An element preceded by “a” or “an” does not,without further constraints, preclude the existence of additionalidentical elements in the process, method, article, or apparatus thatcomprises the element.

Unless otherwise stated, any and all measurements, values, ratings,positions, magnitudes, sizes, and other specifications that are setforth in this specification, including in the claims that follow, areapproximate, not exact. Such amounts are intended to have a reasonablerange that is consistent with the functions to which they relate andwith what is customary in the art to which they pertain. For example,unless expressly stated otherwise, a parameter value or the like mayvary by as much as ±10% from the stated amount.

In addition, in the foregoing Detailed Description, it can be seen thatvarious features are grouped together in various examples for thepurpose of streamlining the disclosure. This method of disclosure is notto be interpreted as reflecting an intention that the claimed examplesrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, the subject matter to be protected liesin less than all features of any single disclosed example. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separately claimed subjectmatter.

While the foregoing has described what are considered to be the bestmode and other examples, it is understood that various modifications maybe made therein and that the subject matter disclosed herein may beimplemented in various forms and examples, and that they may be appliedin numerous applications, only some of which have been described herein.It is intended by the following claims to claim any and allmodifications and variations that fall within the true scope of thepresent concepts.

What is claimed is:
 1. A process, comprising: providing an electroniceyewear device frame insert composed of a first material; providing amold for the electronic eyewear device frame insert, wherein theelectronic eyewear device frame insert comprises a releasably mountablefeature for releasable attachment to the mold which does not interferewith overmolding of areas of the electronic eyewear device frame insertnot comprising the releasably mountable feature, wherein the releasablymountable feature includes at least one eye lens rim; inserting theelectronic eyewear device frame insert into the mold and releasablymounting the at least one eye lens rim of the electronic eyewear deviceframe insert to the mold in a desired position and not contacting otherareas of the mold; filling the mold with a second material in an amountsufficient to cover the electronic eyewear device frame insert to adesired coating thickness; allowing the second material containing theelectronic eyewear device frame insert to solidify; and removing fromthe mold an overmolded electronic eyewear device having the electroniceyewear device frame insert partially encased with the second materialto produce an overmolded electronic eyewear device.
 2. The process ofclaim 1, further comprising assembling one or more parts to theelectronic eyewear device frame insert prior to inserting the electroniceyewear device frame insert into the mold.
 3. The process of claim 2,wherein the one or more parts include a flexible printed circuit board(PCB) or antenna.
 4. The process of claim 2, wherein the one or moreparts includes a decorative feature.
 5. The process of claim 1, whereinthe first material has a Shore Hardness that is substantially identicalto the second material.
 6. The process of claim 1, wherein the secondmaterial is different from the first material.
 7. The process of claim6, wherein the second material has a lower Shore Hardness than the firstmaterial.
 8. A process according to claim 7, wherein the first materialhas a Shore D Hardness of between about 80 to about 85 and the secondmaterial has a Shore A hardness of between about 60 to about
 70. 9. Theprocess of claim 7, wherein the second material is a rubber material.10. The process of claim 1, wherein the first material comprises athermoplastic.
 11. The process of claim 1, wherein the first material istransparent.
 12. The process of claim 1, wherein the first material is ametal or metal composite.
 13. The process of claim 1, wherein the atleast one eye lens rim comprises a groove.
 14. The process of claim 1,wherein the mold is a horizontal injection molding machine.
 15. Anovermolded electronic eyewear device produced by the process of claim 1.16. The overmolded electronic eyewear device of claim 15, wherein theovermolded electronic eyewear device comprises one or more parts atleast partially encased within the overmolded layer.
 17. The overmoldedelectronic eyewear device of claim 15, wherein the second material has alower Shore Hardness than the first material.
 18. The overmoldedelectronic eyewear device of claim 17, wherein the first material has aShore D Hardness of between about 80 to about 85 and the second materialhas a Shore A hardness of between about 60 to about 70.